armstrong



I Sept. 6, 1932.

L. E. ARMSTRONG HEAT AND SOU ND INSULATING BOARD AND BLOCK Filed m. 9, 1950 ww/mz wm Inv e no r; W 8. r

Patented Sept. 6, 1932 UNITED STATES PATENT OFFICE LOUIS E. ARMSTRONG, OF FORT DODGE, IOWA, ASSIGNOR TO INSULEX CORPORATION,- OF CHICAGO, ILLINOIS, A CORPORATION OF DELAWARE HEAT AND SOUND INSULATING BOARD AND BLOCK Application filed October 9, 1930. Serial No. 487,431.

. My invention relates to heat and sound insulating boardand blocks and the method of producing the same, and it has for its object the provision of a new and improved form and arrangement of parts in a structure of this type whereby very effective results may be attained in the matter of i-.sulation while at the same time the strength of the structure shall be such as to insure the builders being able to handle the blocks and board to the necessary extent for the shipping and building operations without undue danger of breakage.

For insulation purposes, a light cellular material havin a very great number of minute closed air cells of substantially uniform size and preferably closed off completely from each other is desirable, such material being formed of mineral matter so as to aflford protection against fire and vermin. Such material is available'in the form of the product known commercially as Insulex,

prepared substantially in accordance with the teachings of Ashenhurst Reissue Patent No. 15,952 of November 25, 1924. It has been found very diflicult, however, to obtain the required adhesion between a layer of this materlal and a strengthening element such as a paper liner or the like, and it is one of the objects of myinvention to provide an improved arran ement b reason of which the desired adhesion may I secured.

- It is one of the objects of my invention to provide an effective structure of this type so arranged as to make possible its production cheap y and easily upon a commercial basis. It is still another object of my invention to improve products of this type and the method inafter pointed out. The preferred means of producing the same in sundrydetails here- Fig. 2 is an elevationalview of a block embodying my improvements; 1 I

Fig. 3 is a vertical cross section through a partially completed block in position m a" mold, showing in dotted lines a completed ,55 portion of the block; and

Fig. 4 is a perspective view of a fragmentary portion of a board or block showing a modi 16d form of my invention.

Referring now to Fig. 1 of the drawing, 10 and 11 indicate sheets of fibrous material preferably in the form of paper, having between them a layer 12 of set and hardened plastic material comprising gypsum as its principal ingredient, the layer 12 being preferably of the type of material ordinarily employed for the body of a piece of plaster board or wall board. Upon the outer face of the sheet 11 in the construction shown, thereis provided a comparatively much thicker layer 13 of 7Q set and hardened plastic material of very considerably lighter weight than the material forming the layer 12, the layer 13 preferably also comprising gypsum as its prlncipal ingredient. Upon the layer 13, I have pro- 7 vided a sheet of insulating material 14, preferably in the form of a heav sheet of paper formed from a rather coarse y matted material such as shredded or comminuted corn stalks. The sheet If may be made of a combination of materials matted together such as shredded corn stalks and straw and, if desired, the materials may be impregnated or. mixed with'a thin slurry of calcined gypsum and water which will render the finished sheet highly resistant to fire.

.In practice, I have had very good results in the preparation of the body or core portion of my improved board and blocks by the use of a mixture of the following ingredients, pounds of calcined gypsum, 2 ounces of commercial retarder, 3% pounds of a suitable carbonate, such as calcium carbonate, and 8 pounds of aluminum sulphate 5 containing water of crystallization, all of such ingredients being finely ground and thoroughly mixed in a dry state. In using such mixture, sufiicient water is added for producing a mixture of such consistency as to cause it to flow readily, such water being adapted to combine with the different ingredients named for causing the production of a mass of cells filled with air or other gas of such a character as to set and harden in such cellular condition. With the ingredients as named above, I have been able to provide a layer of material having a weight of substantially eighteen pounds per cubic foot.

In the preparation of the product as shown in Fig. 1, I preferably employ a machine of the well-known wall board type comprising means for carrying the sheet 0 paper 10 forward, means for depositing the material comprising the layer 12 in plastic condition upon the sheet 10, means for applying the sheet 11 on top of the layer 12 and for applying pressure thereon for producing a product of even thickness, means for depositing the plastic material of the layer 13 on top of the sheet 11,

and means for applying the sheet 14 on top of the layer 13,all by a continuous process as is well understood in the art.

In the preparation of my board, the sheets of paper 10 and 11 and the intervening layer 12 comprise in effect a wall board structure which when dry has the normal strength and stiffness of wall board. By reason of the strength and stiffness of the portion of my product comprising the sheets 10 and 11 and the interposed wall board layer 12, the layer 13 is caused to have a strong bonding engagement with the outer face of the sheet 11. The strength of the adhesion between any given small portion of the sheet 11 and the corresponding portion of the layer 13 is comparatively small, but when the relative positions of the sheet 11 and the body 13 are maintained permanently unchanged by reason of the stiffness and strength of the wall board portion, the aggregate strength of the adhesion of the different portions of the face of the sheet 11 with the corresponding portions of the body 13is sufiicient for providing effective bonding of the two parts together. For bringln about this result, it is necessary that the product be permitted to complete its initial set more or less completely before any effort is made to handle the product independently of the support provided by the wall board machine, if the best results are desired with respect to the adhesion of the layer 13 with the sheet 11.

I have found in practice that with the layer 13 bonded to the sheet 11 as above described, strengthened by its relationship to the layer 12 and the sheet 10, under such circumstances the. comparatively stiff heavy sheet 14 of paper is adapted also to have a strong bonding relationship to the layer 13.

The construction shown in Fig. 2 is referably the same as that above describe except that the product is in the form of a block of any approved size and shape as distinguished from being merely a fragmentary portion of a board. The parts as shown in Fig. 2 are accordingly provided with the same reference characters.

While the block shown in Fig. 2 may be cut from a piece of board prepared as above described upon the well-known wall board machine, I prefer under some circumstances to employ a different method. In Fig. 3, I have shown a table 15 having a smooth upper face upon which a mold 16 of any approved size and shape may be placed, such mold 16 comprising merely side and end walls, being open at both its top and its bottom faces. With the mold 16 in position upon the table 15, I place a piece of wall board 17 in the mold after having fitted the same carefully to the mold. I then fill the mold above the wall board 17 with a layer of the plastic material substantially to the top edge of the mold, after which I level and screen the material to a point below the upper edge of the mold 16 so as to permit the insertion of the top sheet of paper. I have indicated the layer of plastic material diagrammatically in dotted lines by the numeral 18 and the sheet of paper by the numeral 19 in said Fig. 3. I have found in practice that when a block is produced in this manner the adhesion between the layer 18 and the wall board and that between the layer 18 and the stiff heavy sheet 19 of paper are sufficient for holding the parts intact under normal conditions of shipping and building operations.

Referring now to Fig. 4 of the drawing, 20 indicates a relatively thick body of highly cellular material similar to the layers 13 of the forms shown in Figs. 1 and 2. The body 20 is bonded at one face to a plaster board 21 and at its other face to a sheet of material 22. The board 21 may be a plaster board'comprising layers 10, 11 and 12 similar to that of Figs. 1 or 2 or it may be a relatively thick sheet of fibrous material suitable as a plaster base such as comminuted or shredded corn stalks, straw or the like. The sheet 22 may be formed of material similar to that employed in the base sheet 21 and as hereinbefore described the sheet 22 and also the sheet 21, if desired, may be impregnated or mixed with a thin slurry of calcined gypsum and water to fireproof them.

The product shown in Fig. 4 is well adapted for absorbing sound. It may be made in convenient sizes secured in place on the walls and ceilings of a room by nailing, cementing or otherwise attaching the base portion 21 thereof to the wall. When the product is to be used for the purposes just described its sound-absorbing properties may be increased by punching or otherwise providing holes or perforations 23 which extend through the sheet 22 and either through or a substantial distance into the body portion 20, it being understood that the blocks are installed with the base 21 against the wall so that the face having the openings 23 .is exposed on the interior of the room for the reception of sound waves.

Products embodying the principles of my invention are highly efficient from an insulation standpoint and may be used as liners in. walls, floors, ceilings and roofs as effective insulation in many different types of buildings and structures. The products are capable of withstanding the ordinary jarring and shocks incident to handling, trucking or shipping without breakage.

Board as shown in Fig. 1 is reversible. It may be nailed to the wall studs with the liner 14 next to the studs in which case the liner 1O presents a smooth finished surface for papering, painting or other decorative material.

When the board is reversed and is applied to wall studs with the liner 10 adjacent the studs, the liner 14 of corn stalks or other similar material provides an ideal surface over which plaster may be applied. The board may also be cut into strips and used as an effective insulation liner between the studs of a wall.

While I prefer to employ substantially the form of parts as illustrated in my drawing and as above described, it is to be understood that my invention is not limited thereto except so far as the claims may be so limited by the prior art.

I claim 1. In a product of the type described, the combination of two liners of fibrous material, a layer of plastic material comprising gypsum as the principal ingredient interposed between said two liners in bonded relationship thereto a comparatively much thicker layer of comparatively much lighter cellular plastic material also comprising gypsum as its principal ingredient bonded to -"the outer face of one of said liners, and athird sheet of fibrous material bonded to the outer face of said second named layer of plastic material.

2. In a product of the type described, the combination of two liners of fibrous mate rial, a layer of plastic material comprising gypsum as the principal ingredient interposed between said two liners in bonded relationship thereto, a comparatively much thicker layer of comparatively much lighter cellular plastic material also comprising gypsum as its principal ingredient bonded to the outer face of one of said liners, and a sheet of insulating material in the form of heavy paper made from corn stalks in bonded relationship upon the outer face of said second named layer of plastic material.

3. In a product of the type described, the combination of a member having the strength and thickness of wall board, a layer of comparatively much lighter cellular plastic material comprising gypsum as its principal ingredient and of comparatively much greater thickness than that of said first named member bonded to one face of said member, and a sheet of fibrous material bonded to the outer face of said layer of plastic material.

4:. In a product of the type described, the combination of a member having the strength and thickness of plaster board, a layer of comparatively much lighter cellular plastic material comprising gypsum as its principal ingredient and of comparatively much greater thickness than that of said first named member bonded to one face of said member, and a sheet of insulating material in the form of heavy paper made from shredded corn stalks or their equivalent impregnated with gypsum and bonded to the outer face of said layer of plastic material.

5. In a product of the type described, the combination of a member having the strength and thickness of plaster board,a

layer of comparatively much lighter cellular plastic material comprising gypsum as its major ingredient and of comparatively much greater thickness than that of said first named member bonded to one face of said member, and a sheet of fibrous material bonded to the outer face of said layer of plastic material, said sheet of fibrous material having a large number of openings which communicate with corresponding openings extending a substantial distance into said layer of cellular plastic material.

6. In a product of the type described, the combination of a member having the strength and thickness of wall board, a layer of comparatively muchlighter cellular plastic material comprising gypsum as its principal ingredient and of comparatively much greater thickness than that of said first named member bonded to one face of said member, and a heavy sheet of insulating material in the form of paper made from corn stalks bonded to the outer face of said layer of plastic material.

7. In a product of the type described, the combination of a piece of gypsum wall board, a layer of comparatively much lighter cellular plastic material comprising gypsum as its principal ingredient and of comparatively much greater thickness than that of the wall board bonded to one face'of said board, and a heavy sheet of insulating material in the form of paper bonded to the outer face of said layer of plastic material.

LOUIS E. ARMSTRONG. 

